PART NO. | SPECIALTY TOOL |
HD-45314 | Crankshaft rotating wrench |
HD-45334 | Secondary cam chain measurement tool |
1. Support engine with a scissors jack under the frame at the fuel tank.
2. Remove the right side cover and maxi-fuse. See 8.5 Maxi-fuse.
3. Unlock and open seat.
4. Remove airbox cover. See 1.4 Airbox and air filter.
Warning! To protect against shock and accidental start-up of vehicle, disconnect the negative battery cable before proceeding. Inadequate safety precautions could result in death or serious injury.
5. Disconnect negative battery cable.
6. Remove air filter top and air filter. See 1.4 Airbox and air filter.
7. Remove the horn. See 8.20 Horn.
8. Remove the derby cover from the left side crankcase cover.
Caution! Turn the engine crankshaft counterclockwise only. Turning it clockwise could cause the cam chain to jump over the cam sprocket.
9. To position the front piston to adjust the secondary cam chain:
- a. See Figure 1-82. Install CRANKSHAFT ROTATING WRENCH (HD-45314).
- b. Hold the throttle wide open and watch front cylinder intake valve through intake port.
- c. Turn crankshaft counterclockwise to open valve fully and then to close the valve.
- d. When the front cylinder intake valve is seated, turn crankshaft an additional 1/4 turn (90°) clockwise (CW).
![](https://motoinstruction.ru/img/harley/2/110890.jpg)
Figure 1-82. Positioning piston
Caution! Never rotate the engine without the secondary cam chain tensioner installed. Cam timing could be changed, causing engine damage.
Note. Do not use the sealing washer from the secondary cam chain tensioner when installing the SECONDARY CAM CHAIN MEASUREMENT TOOL (HD-45334).
10. Remove the secondary cam chain tensioner.
11. See Figure 1-83. install SECONDARY CHAM CHAIN MEASUREMENT TOOL. Thread-in the tool until it is seated against the cylinder head.
![](https://motoinstruction.ru/img/harley/2/110891.jpg)
Figure 1-83. Secondary cam chain measurement tool installed in front cylinder: 1. Secondary cam chain measurement tool; 2. Visible grooves
12. Note the number of grooves showing on the tool.
13. Remove the SECONDARY CAM CHAIN MEASUREMENTTOOL.
14. From the table, select the number of shims necessary for correct secondary cam chain tension. See Table 1-7.
Table 1-7. Tensioner Shims
Grooves | Shims Required |
4 | 1* |
3 | 2* |
2 | 3 |
1 | 4 |
* Do not add shims if start-up rattle is not heard.
Note. If a start-up rattle was noticed, 1 or 2 shims are added to the tensioner. If there was no start-up rattle, do not add 1 or 2 shims to the tensioner.
15. See Figure 1-84. Wrap cardboard or heavy cloth around thick shaft on plunger (1). Gently twist while pulling to remove plunger (1) from tensioner (3).
![](https://motoinstruction.ru/img/harley/2/110892.jpg)
Figure 1-84. Secondary cam chain tensioner: 1. Plunger; 2. Shims (as required); 3. Secondary cam chain tensioner; 4. Seal
16. Apply a thin film of Harley-Davidson Motorcycle Oil 20W50 to selected shims (2) and plunger (1).
17. Seat number of selected shims (2) and plunger (1) in tensioner (3).
18. Lubricate tensioner seal (4) with Harley-Davidson Motorcycle Oil 20W50.
19. Install front cylinder secondary cam chain tensioner. Tighten to 100 Nm (74 ft-lbs).
Caution! Turn the engine crankshaft counterclockwise only. Turning it clockwise could cause the cam chain to jump over the cam sprocket.
20. To position rear cylinder to adjust secondary cam chain:
- a. See Figure 1-82. Install CRANKSHAFT ROTATING WRENCH (HD-45314).
- b. Hold throttle wide open and watch rear cylinder intake valve through intake port.
- c. Turn crankshaft counterclockwise to open valve fully and then close intake valve.
21. When rear cylinder intake valve is seated, turn crankshaft an additional 1/4 turn (90°) clockwise (CW).
Note. Do not use the sealing washer from the secondary cam chain tensioner when installing the SECONDARY CAM CHAIN MEASUREMENT TOOL (HD-45334).
22. See Figure 1-83. Remove rear cylinder secondary cam chain tensioner and install SECONDARY CHAM CHAIN MEASUREMENT TOOL. Thread-in the tool until it is seated against cylinder head.
23. Note the number of grooves showing on tool.
24. Remove SECONDARY CAM CHAIN MEASUREMENT TOOL.
25. See Table 1-7. From the table, select the number of shims necessary for correct secondary cam chain tension.
Note. If a start-up rattle was noticed, 1 or 2 shims are added to the tensioner. If there was no start-up rattle, do not add 1 or 2 shims to the tensioner.
26. See Figure 1-84. Wrap cardboard or heavy cloth around thick shaft on plunger (1). Gently twist while pulling to remove plunger (1) from tensioner (3).
27. Apply a thin film of Harley-Davidson Motorcycle Oil 20W50 to selected shims (2) and plunger (1).
28. Seat number of selected shims (2) and plunger (1) in tensioner (3).
29. Lubricate tensioner seal (4) with Harley-Davidson Motorcycle Oil 20W50.
30. Install rear cylinder secondary cam chain tensioner. Tighten to 100 Nm (74 ft-lbs).
31. Install the horn. See 8.20 Horn.
32. Connect negative battery cable.
33. Install air filter and air filter top. See 1.4 Airbox and air filter.
34. Install airbox cover.
35. Install the right side cover and maxi-fuse.
Warning! When closing the seat, make sure the ignition switch is in the FUEL position. If the ignition switch is in any other position when the seat is closed, the seat latch mechanism could be damaged.
36. Turn ignition switch to FUEL and close seat. Then turn ignition switch to LOCK.
Warning! After installing and locking seat, pull upward on the latch side of the seat to be sure it is locked in position. If seat is loose, it could shift position during vehicle operation resulting in loss of control of the vehicle and death or serious injury.